Vission 20/20 Retrofit Instructions - Emerson Electric

Vission 20/20 Retrofit Instructions

3ViSSion® 20/20 Retrofi t Instructions • 35391SCRF

Table of Contents

Sections Page

1.0 General Information ................................................................................................................ 32.0 Vission 20/20 Retrofi t Instructions .......................................................................................... 42.1 Removal ................................................................................................................................. 42.2 Installation .............................................................................................................................. 53.0 Field Wiring Instructions ......................................................................................................... 9

Table/Figures Page

Table 1. Torque Specifi cations .................................................................................................... 12

Figure 1. VSS Compressor Unit with Keypad Microprocessor ....................................................... 4Figure 2. Block and Bleed Assembly ............................................................................................. 5Figure 3. Vission 20/20 with Vibration Isolators .......................................................................... 6Figure 4. Block and Bleed Assembly with Transducers .................................................................. 6Figure 5. Compressor Unit RTD Locations .................................................................................... 7Figure 6. Block and Bleed Assembly with Transducers and Cables ................................................ 8Figure 7. RTD and Transducer Cable Routing ............................................................................... 8Figure 8. Solenoid Cable Routing ................................................................................................. 9Figure 9. MCC and Customer Control Center Interconnect Wiring ............................................... 10Figure 10. Vission 20/20 Mircocontroller Diagram ......................................................................... 10Figure 11. Vission 20/20 Terminal Blocks ....................................................................................... 11

1.0 General Information

This procedure defi nes the steps required to replace a Vilter Keypad Microcontroller with the Vission 20/20 Microcontroller.

It is highly recommended that the instructions be reviewed prior to retrofi tting.

Figures and tables are included to illustrate key concepts.

Safety precautions are shown throughout the manual. They are defi ned as the following:

WARNING - Warning statements are shown when there are hazardous situations, if not avoided, will result in serious injury or death.

CAUTION - Caution statements are shown when there are potentially hazardous situations, if not avoided, will result in damage to equipment.

NOTE - Notes are shown when there are additional information pertaining to the instructions explained.

4 ViSSion® 20/20 Retrofi t Instructions • 35391SCRF

2.0 Vission 20/20 Retrofi t Instructions

This procedure defi nes the steps required to replace a Vilter Keypad Microcontroller with the Vission 20/20 Microcontroller.

2.1 Removal

Step 1. Safely shutdown and de-energize the compressor unit (1) and keypad microcontroller (2) adhering to safe practices including lock-out/tag-out procedures.

Figure 1. VSS Compressor Unit with Keypad Microprocessor

Step 2. Disconnect wiring from transducers.

WARNINGWhen handling microcontroller, use additionalpersonnel or lifting device as required. Failure tocomply may result in serious injury and/or damage to

equipment.

Step 3. With additional personnel or lifting device, remove hardware securing keypad microcontroller (2) to rails (4). Remove keypad mirocontroller.

NOTE

Some compressor units are equipped with transducers and RTDs, if equipped, continue to step 3. If not, continue to installation.

Step 4. Disconnect all associated pressure and temperature sensors from compressor unit (1) and existing block and bleed assembly (3), if present.

Step 5. Remove the existing block and bleed assembly (3), if present.


2.2 Installation

NOTE

Torque all hardware according to torque table specifi cations, see Table 1.

NOTE

Modifi cation to rails may be required to support and properly align Vission 20/20 microcontroller and block and bleed assembly. Follow standard practices for

weldment and fabrication procedures.

Step 5. Install new block and bleed assembly (4) on rails (3).

Figure 2. Block and Bleed Assembly

WARNINGWhen handling microcontroller, use additionalpersonnel or lifting device as required. Failure tocomply may result in serious injury and/or damage to

equipment.

NOTE

On smaller compressor units, ensure there is adequate clearance between Vission 20/20 microcontroller and volume slide actuator. Adjust location of

microcontroller as required by modifying support structure.

Step 6. Make sure Vission 20/20 microcontroller will install onto existing rails. Measure mounting holes on rails (3) and Vission 20/20 microcontroller (6), taking into consideration dimension of mounting holes of vibration isolators (5).

Step 7. Modify structure of rails (3) if required. Follow standard welding and fabrication procedures.


Step 8. Install hardware to secure new vibration isolators (5) to mounting holes of Vission 20/20 microcontroller (6).

Figure 3. Vission 20/20 with Vibration Isolators

Step 10. With additional personnel or lifting device, install hardware to secure Vission 20/20 microcontroller (6)with vibration isolators (5) to rails (3).

NOTE

Ensure to use correct transducers because transducers have different pressure ranges. Suction manifold uses 0-200 psia transducer, discharge manifold and oil

fi lter inlet uses 0-414.5 psia transducer.

Step 9. Install transducers (7) on block and bleed assembly (4).

Figure 4. Block and Bleed Assembly with Transducers


NOTE

Stainless steel tubing is not provided in a retrofi t kit.

Step 10. Route stainless steel tubing from suction manifold, discharge manifold and oil fi lter inlet lines. If existing tubing is not reusable then cables can be secured to block and bleed assembly (4).

NOTE

Wells are also provided in retrofi t kit. Install new wells as required.

Step 11. Install RTDs (8) on suction manifold (9), discharge manifold (11), oil separator (12) and inlet oil line (14) or oil manifold (13), if equipped.

Figure 5. Compressor Unit RTD Locations

Step 12. Connect cables (10) to RTDs (8).


Step 12. Connect cables (10) to transducers (7).

Figure 6. Block and Bleed Assembly with Transducers and Cables

Step 13. Route cables (10) from RTDs (8) and transducers (7) through bottom right side of Vission 20/20 microcontroller (6).

Figure 7. RTD and Transducer Cable Routing


CAUTIONDo not route A/C and D/C wires together, this willcause Electromagnetic Interferance. Failure to comply

may result in damage to equipment.

Step 14. If equipped with solenoids (15) (i.e. Danfoss Motorized Valve), route cables (16) from solenoids through bottom left side of Vission 20/20 microcontroller (6).

Figure 8. Solenoid Cable Routing

Step 15. To make following connections according to supplied wiring diagram, refer to Section 3.0 Field Wiring Instructions.

3.0 Field Wiring Instructions

NOTE

This procedure defi nes steps required to wire Vission 20/20 microcontroller for the following items: Compressor Motor Starter Auxiliary Contact, High Level

Shutdown, Oil Separator Heater(s), Oil Pump Start and Compressor Starter.

General fi gures, Figures 9, 10 and 11 are used for purposes of explanation, follow supplied wiring diagram for detailed wiring.

Step 1. Control power of 115 VAC 50/60 HZ must be wired to left side of terminal blocks inside the Vission 20/20 cabinet. Line power (1A) shall be connected to 15-amp circuit breaker, CB1. Neutral (1N) is connected to any N terminal blocks. Number of line power feeds required to panel is dependent upon number supplied on compressor. Line power feeds for oil heaters are brought to additional 15-amp circuit breakers, CB2A, CB2B, CB2C and CB2D. Neutrals for circuits (2N, 3N, 4N, and 5N) are connected to terminal blocks labeled HTN2, HTN3, HTN4, and HTN5. Units with V-PLUS® oil cooling, L1 must connected to fuse in V-PLUS panel, and L1A must be connected to terminal 2B.


Step 2. An auxiliary contact from compressor motor starter is required. Connect isolated contact to terminal blocks 1 and 31.

19

18

17

16

14

15

13

9

12

11

10

8

7

6

4

5

3

2

1

115VAC / 60HZDOORGND LUG

1A

DC POWER SUPPLIES

N1CONTROL POWERDISCONNECT AND BRANCH CIRCUIT PROTECTION TO BE

SIZED PER THE NATIONAL ELECTRIC CODE.INCOMING POWER SUPPLIED FROM REMOTE CUSTOMER SUPPLIED UL LISTED FUSED DISCONNECT OR BREAKER

15 AMPSCB 1

SW 1E-STOP

LINELOADEMI FILTER

TO CPU BASEBOARD

OUTPUTS

13

14

16

15

OIL SEPARATOR HEATER START74, 78

17

18 HHH OPTIONAL TRIP INDICATION

OUTPUT CAN ALSO BE USED WITH AN INDICATING LIGHT, HORN, OR PLC INPUT (CUSTOMER SUPPLIED)

GND

DIGI

TAL O

UTPU

T: BO

ARD

#1

PLUG

X1

DIGI

TAL O

UTPU

T: BO

ARD

#1

PLUG

X2

INPU

T

1C 2

OU

TPU

T +5VDC+12VDC5/12 COM

GND

OUTPUTS

N

N

1B1GND

RD-35-A

CRHA1 A2

1

1

N

N

N

N

N

H

5

6

7

8

H

4

3

2

1

RS-50-24

OU

TPU

T

INPU

T +24VDC

24 COM

COMPRESSOR STARTER70

OIL PUMP STARTER73

50

49

48

47

46

44

45

43

42

41

40

32

33

35

34

36

37

38

39

51

52

53

54

FROM LINE 31 FROM LINE 31

31

32

33

34

AUX MS1

HLSHUTDOWN AUX

COMPRESSOR MOTOR STARTER AUXILIARY CONTACT

HIGH LEVEL SHUTDOWN

OPTIONAL OIL LEVEL FLOAT SWITCH #1

OPTIONAL OIL LEVEL FLOAT SWITCH #2

OPTIONAL REMOTE CAPAPCITY DECREASE

OPTIONAL REMOTE CAPACITY INCREASE

OPTIONAL REMOTE START/STOP

OPTIONAL CAPACITY CONTROL SELECT 1/2

38

37

36

35

DIGI

TAL I

NPUT

: BOA

RD #3

PL

UG X

1DI

GITA

L INP

UT: B

OARD

#3

PLUG

X2

INPUTS

INPUTS

1

1

1

1

1

1

1

1

N

N

8

7

6

5

N

1

2

3

4

N

N

CROP

CRCMP

11A

12A

*SEE NOTE 10

A1

A2*SEE NOTE 10

BLACK

BLUE

BROWN

BLUE

BLACK

VOLUME INCREASE/DECREASE ACTUATOR

CAPACITY INCREASE/DECREASE ACTUATOR

BROWN

LOW OIL LEVELLS1

Figure 10. Vission 20/20 Mircocontroller Diagram

Step 3. A dry contact from control relay CR11 must be wired to compressor motor starter coil. This dry contact is wired to terminal blocks according to supplied drawing. Control power for this coil should come from a source, which will be de-energized with compressor disconnect.

VISSION 2020 ON COMPRESSOR SKID CUSTOMER MCC PANEL(REFERENCE MCC OR STARTER DRAWING FOR DETAILED WIRING)

OIL PUMP START

COMPRESSOR MOTOR STARTER AUX CONTACT

OIL SEPARATOR HEATER START

AUX MS1

COMPRESSOR MOTOR STARTER AUX CONTACT

TB-1

TB-31

CUSTOMER SUPPLIED VISSION POWER CIRCUIT N

OIL PUMP STARTCOMMAND

OIL SEPARATOR HEATER START COMMAND

COMPRESSOR STARTCOMPRESSOR STARTCOMMAND

CB1

TB1-1A

TB1-N

TB1-18 TB1-4

TB1-11

TB1-12

TB1-17

TB-11

TB-12

TB-17

VISSION 20/20 POWER

#12AWG THHN (MINIMUM)

Figure 9. MCC and Customer Control Center Interconnect Wiring


Step 4. A dry contact from control relay CR12 must be wired to oil pump motor starter coil. This dry contact is wired to two terminal blocks according to supplied drawing. Control power for this coil should come from a source, which will be de-energized with compressor disconnect.

Step 5. An auxiliary safety cutout is available to shut down compressor package. A dry contact must be supplied and wired to terminal blocks 1 and 32. The jumper installed on terminal blocks must be removed to use this cutout. If contact is closed, it will allow compressor to run. If contact opens at any time, compressor will shut down.

GNDGNDGND

1

HT-N2

CBA15 2C

CBA15

1CBA15 2C

HT-N1

CBA15 2C

DIGI

TAL W

IRIN

G

CUST

OMER

DIG

ITAL W

IRIN

G

CUST

OMER

ANA

LOG

WIR

ING

C5

5

OPE

N

C4

4321

GNDGNDGND

111111BNNNNN1112131415161718

2827262524232221

3132333435363738

X1

X2

X3

X4

X5

X1

X2

X3

X4

X5

ANAL

OG IN

PUT B

OARD

#7AN

ALOG

INPU

T BOA

RD #6

DIGI

TAL I

NPUT

BOA

RD #3

DIGI

TAL O

UTPU

T BOA

RD #2

DIGI

TAL O

UTPU

T BOA

RD #1

HT-N2

CBA15 2C

CBA15

1CBA15 2C

HT-N1

CBA15 2C

ANAL

OG O

UTPU

T BOA

RD #1

0

45464748

1111BNNNNN

Figure 11. Vission 20/20 Terminal Blocks

Step 6. Indication of compressor shutdown status is also available. There is an output on terminal blocks 18 and N where a relay coil can be wired. For output, an energized state represents a “safe” condition. A de-energized state indicates a loss of voltage to relay coil or a “failure” has occurred.

Step 7. Current transformer supplied in compressor motor conduit box should be checked to insure that motor leads of one leg are pulled through the transformer. Note, there is a dot on one side of the current transformer. This dot must face away from the motor. Typically, a wye delta started motor should have leads 1 and 6 pulled through this transformer for a 6 lead motor. However, this should always be checked as different motors and starting methods will require different leads to be used.


Torque Specifications (ft-lbs)

TypeBolt

HeadMarkings

Nominal Size Numbers or Inches

#10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8

SAE Grade 2

Coarse (UNC)- 5 10 18 29 44 63 87 155 150*

SAE Grade 5

Coarse (UNC)- 8 16 28 44 68 98 135 240 387

SAE Grade 5

Coarse (UNC)- - 18 - - - - - - -

SAE Grade 8

Coarse (UNF)- 11 22 39 63 96 138 191 338 546

Socket Head

Cap Screw

(ASTM A574)

Coarse (UNC)

5 13 26 46 73 112 115 215 380 614

1) Torque values in this table are not to override other specifi c torque specifi cations when supplied.

2) When using loctite, torque values in this table are only accurate if bolts are tightened immediately after loctite is applied.

* The proof strength of Grade 2 bolts is less for sizes 7/8 and above and therefore the torque values are less than smaller sizes of the same grade.

Torque Specifications for 17-4 Stainless Steel Fasteners (ft-lbs)

TypeBolt/Nut

HeadMarkings

Nominal Size Numbers or Inches

#10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

Hex & Socket Head Cap Screws

3 8 14 25 40 60 101 137 245

Nut - 8 - 25 - - - - -

NOTE: Continue use of red loctite #271 (VPN 2205E) on currently applied locations. Use blue loctite #243 (VPN 2205F or 2205G) on all remaining locations.

Table 1. Torque Specifi cations

35391SCRF Rev. 1 (4/13) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affi liated companies. © 2012 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.

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Vission 20/20 Retrofit Instructions - Emerson Electric